Method for the production of pile fabrics



July 8, 1941. w. o. STODDARD METHOD FOR THE PRODUCTION 0]? FILE FABRICS Filed April 25, 1938 3 Sheets-Sheet 1 INVENTOR 1 ATTORNEY;

y 1941- w. o. STODDARD' I METHOD FOR THE PRODUCTION OF FILE FABRICS Filed April 25, 1938 3 Sheets-Sheet 2 mmm Q'J/MJM INVENTOR awe/$5M A1TORNEY5 y 1941- w. 0. STODDARD METHQD FOR THE PRODUCTION OF FILE FABRICS s Sheets-Sheet 3 Filed April 25, 1938 l W/fam Q fifaaciQ/d INVENTOR 4 WM! ATTORNEYS Patented July 8, 1941 METHOD FOR THI PRODUCTION OFPILE FABRICS William 0. swam. Detroit, Mich. Application April 25, 1938, Serial No. 203,991

ZCiaims.

This invention relates to a method for the production of a pile fabric and is more particularly directed to the fabrication of pile or tufted fabrics which have a plurality of threads, fibers or other pile forming material arranged to form the pile portion of the fabric, secured to a suitable backing material.

An important object of this invention is the provision of supporting and spacing means for certain portions of a suitable pile forming material during a plaiting operation in association with means for applying a backing material thereto whereby the material retains its pleated formation.

A particular object of the present invention is the provision ofnovel means for temporarily supporting plaits of the pile forming portion of fabric during the application of suitable backing material thereto.

A further object of the invention is an arrangement whereby a pliable sheet or creasable material is fed and guided to the material to be plaited and whereby both 'areconcurrently and contiguously plaited and the creasable material removed therefrom-..

A further object of the invention is the operation of simultaneously plaiting a relatively stiff yet plaitable material such as paper, sized cloth, woven fabric or the like constituting a supporting web with the plaiting of the pile forming material of the fabric for the purpose of properlv spacing the plaits and maintaining the plaited material in even rigid rows during the cementing of a relatively inexpensive backing such as burlap or the like to the pile forming material immediately after the plaiting operation whereby sufficient pressure may be employed to series of steps to produce a tuft fabric thereby enhancing the rapidity of production.

Another object of the invention is to include in the method the guiding and feeding of spun or unspun yarn or the like from a source of supply in a manner which provides a uniform density of the fibers forming a sheet material.

A still further object of the invention contemplates the inclusion of synchronized feeding for providing a uniform flow of material from a source of supply to a forming apparatus.

Further objects and advantages are within the scope of this invention such as relate to the arrangement, operation and function of the related elements of the structure, to various details of construction and to combinations of parts, elements per se, and to economies of' manufacture and numerous other features as will be apparent effect a strong permanent anchoragebetween the two main portions of the completed fabric.

A further object of the invention is the operation of simultaneously plaiting a relatively stiff material as paper or the like as a supporting web with the plaiting of the pile forming material for the purpose of spacing the plaits and maintaining the plaited material in even rigid rows during the application of backing material immediately after the plaiting of the material whereby sufflcient pressure-is applied to effect a strong permanent anchorage.

One object of the invention resides in the provision of the method in which a suitable pile forming material such as yam, threads, fabric or a sheet of 'a plurality of unwoven flbers or filaments are anchored or fabricated into sheet formation on which are performed a continuous from a consideration of the specification and drawing of a form of theinvention, which may be preferred, in which:

Figure 1 is a view illustrating diagrammatically the apparatus and sequence of steps of my invention in the formation of-pile fabric;

Figure 2 is a view showing diagrammatically in detail certain steps of the process of my invention; a

Figure 3 is an enlarged sectional view illustrating the formation imparted to the material after certain steps of the method of my invention'has been carried out; v

Figure 4 is an enlarged sectional view illustrating the formation imparted to the material at a subsequent step to the one, shown in Figure 3;

Figure 5 is an enlarged view illustrating a step in the method of my invention wherein the material is cut to produce two similar pile fabrics;

Figure 6 is an enlarged sectional view of the material illustrating the 'pile fabrics produced after the cutting step shown in Figure 5 has been completed;

Figure '7 is an enlarged sectional viewof the pile fabrics produced by the method of my invention arranged to show the relation of the loops with respect to the spacing of the upstanding pile fabric rows. 1

In general, the method of making pile fabric in accordance with my invention includes the baril isjransmitted through synchronouslyto the push bar 2i.

the proper consistency, the purpose of which'is v to support and space the folds or plaits of the sheet material in even rigid rows. while a backing is applied and bonded or cemented to the folds constituting one side of the plaited material so that the upstanding rows have certain predetermined spacing. The plaited material, supporting web and backing with its cementitious bond is then passed between a series ofheating units which serve to 'dry the bond and permanently secure the folds in proper spaced ,relation to the backing. and the supporting web-is then removed from the plaited material. The plaitedbacked The pull bar It supp rts a material contacting arm 24 having the extreme end adapted to contact with the sheet of material l'l, while the push bar 2| supports a material contacting am having the extremity 8i adapted to contact with the sheet material II. It should be noted that reciprocatory movement imparted to the pull bar it will be transmitted to the push-bar 2| and dueto the particular arrangement of the material contacting members 24 and 26 their respective ends 30 and 3| will contact with the material without the supporting web is fed through additional heating units to'evaporate any solvents and complete the fixing operation while the structure is fed to a. position where a backing is applied and bonded or cemented to the folds forming the opposite side of the pla'ited ma.- terial, the resulting structure is then subjected to suitable heating or. a solvent removing operation whereby this backing material is permanently secured to the plaits. The plaited and backed structure is subjected to a solvent removing operation by the use of one or more suction members positioned at the side or open ends sheet material I! and move 'it along the table is during the forward stroke. The pull bar II and the cooperating push bar 2i will function to drawthe yarns through the reeds i3 and I4 and at the same time pushing the sheet material or flat layer of yarns i1 along the table i9 to the plaiting mechanism which may comprise any of the composite structure. The composite struc,

ture is then split longitudinally or substantially midway between the backings in order to produce 'two similarly formed pile fabrics.

It is to be understood that any suitable material forming the pile fabric of the invention-may be used in connection with the process or that a loom may be incorporated therein and the sheet material woven thereby fed directlygto the plaiting apparatus. It is also contemplated that a roll of prefabricated sheet material, formed with suitable pile elements or fibers may be used in conjunction with the invention, the sheet material being fed directly to the plaiting apparatus. It is contemplated that any suitable machinery may be used in connection with the invention but it has been found that by the incorporation of certain improvement-s therein the product may,"

anism inclusive of a pull her ll which cooperates witha table or support I! to give to the yarnsdrawn through members ll and I4 a hat formation suitable for plaiting.

, As'particularly shown in more detail in ingure 2, the flat sheet material if is conveyed along the stationarytable is by the rcoiprocatory. movement imparted to the'pull bar i'land the interconnected push bar II. The pull bar-J8 and push bar 2! are synchronously reciprocated by suitable mechanism incorporatinga suitable source of power and are interconnected through means of link or connectingme'mberu which is pivotally secured at one end to the pullbar i8 throughthe medium of stud 21 and at its other end to the push bar 2i through the'medium of the stud 28 whereby reciprocatory motion of the the member i .3! and "so that all these members coact to standard machine including the plaiting knives I! and SI. I v

The relative. position and interconnection of,

the pull bar it with the push bar 2! whereby their movement is in proper timed relation provides a mechanism wherein they pull bar draws 'suilicient yarn orsuitable material through the reeds i3 and i4 and concurrently relieves any pulling strain on the sheet formation l1. by the action of the push bar' providing an arrangement for the uniform flow of sheet material through' the table l9 and'their combined timed action msures the accurate and uniformdelivery of the sheet material to the plaiting mechanism.

, The supporting base or table is as particularly-- illustrated has one end located adjacent to the reeds i3 and il while the other end is adjacent to plaiting knives '32 and 33. The table It supports transversely extending sets of reciprocable spaced plates l5, l6 and 35' and 86' one above the other and between which the supporting web It supplied from a roller 39 is fed to the plaiting knives by the reciprocatpry action imparted thereto through the pull bar It and push bar 2|. The, plates 35 and 88 are connected to the lateral side walls'of the pull bar I d by means of connecting rods 40 each pivotally secured at one end toa portion of'the pull bar I, the other end of which is received in aligned openings 39 and 39' located at one-end of these plates. The extreme end portion 40' of theconnecting rod 40 is free to reciprocate in a slot 4| provided in the table II which arrangement also serves to prevent lateral motion of the plates 35 and @8. The

plates II and SI are connected to the push bar 21 through connecting rods 48 by an arrangement similar to thatof plates l8, 38. The connection of the plates and connecting rods 40 and. being such that binding of the related parts is prevented. The platesli, 38 and 35', 88' serve to feed and guide the web 38 to a position directly below the sheet material i1 adjacent to the plaitin'g knives 32, 33 and also prevents contacting engagement between the sheet material II which is conveyed along the top surfaces of plates "and SI" and the supporting web 88 prior to the. plaiting step. thus preventing any crawling or side motion being impartedto the yarn or bat of fibers forming the sheet material I! by theweb ll. The reciprocatory movement of pull bar It and push bar-2| as well as that of the plates 85, It and II, 3|, is in proper timed relation'with the action and movementrof the plaiting knives withdraw the sheet material I! and web 38 from 4 the source ofsupply. The coaction of the re ciprocable members-with the pla-iting knives be- I1. I have found drawing back of either the sheet material H or the web 38.

The plaiting knives 32 and 33 operate in a well known manner to simultaneously hold the sheet material I! and the web 38 so that rigid folds or plaits of sheet material and supporting websare formed. 4

As particularly bined plaited structure formed of the sheet material l1 and the supporting web 38 after leavingthe plaiting knives 32 and 33 is fed or passed through the guiding lips 42 and 43 by means of a suitable mechanism including a drawing roller driven by a suitable source of power, The guiding lips 42 and 43 serve to hold and direct the plaits before the same are in contact with the. backing 48 which has an adhesive in the form of rubber cement 54 applied thereto from a hopper 48 by means of a spreading member 5|. idler roller 46 is in close proximity to the straight forward edge of lip 42 and serves to position the backing with its cementitious material in contact with the bights .58 of the plaited material H.

The idler roller 48 is adjustable with respect to v the plaited material l1 in order that suflicient edgewlse pressure may be exerted by the backing 48 to the plaited material l'l supported by web 38 to insure proper bonding of the rubber cement 54. The backing material 48 which may be burlap or other inexpensive strong material is withdrawn from a suitable source of supply or roll 53. The stiffening web 38 supports the plaited yarn material l1 to enable the same to withstand sufficient pressure applied by the idler roller 46 so that proper impregnation of the material H by the rubber cement 84 is obtained whereby the fibers of the plaited material is permanently anchored to the backing 48.

As articularly shown in Figure 1 the composite plaited structure formed by the sheet material l1 and web 38 with the cementitious backing 48 are then passed through heating or seasoning unit or oven 60 which vulcanizes or bonds the cementitious backing to the plaited material thus fixedly securing the plaits in proper spaced relation forming a plaited backed material 58. It should be noted that the heating unit 88 is in close proximity to the roller 48 whereby the heat applied. to the plaited backed material produces a sufficlentiy strong bond between the cementitious backing material 48 and the plaited material I! so that the web 38 can be withdrawn without affect ng the formation of the plaited material H. The immediate introduction of the composite structure with the cementitious backing within the heating unit 80 enhances the rapid fixation of the folds or plaits to the backing material and prevents any distortion or disruption of the, folds. The web 38 which enables the composite plaited structure to withstand the desired pressure for the proper bonding of the backing to the plaited material ll may be in the form of an endless belt or a ,take off roll may be provided to receive the web after it is removed from a plaited material that when a soft fibrous material such as yarn is used to produce the pile fabric, the presence of the supporting web during the plaiting and first backing operation is very necessary in order to insure that the plaited configuration imparted to the yarn will not be destroyed when pressure is applied thereto during the fixation of the cementitious backing and shown inFigure 1, the comthus' preventing comes an unusable mass.

The plaited backed material 58 is conveyed by a suitable source of power through spaced heating units 82 and 83 thereby removing any solvent from the adhesive 54 and completingthe permanent fixation of the backing 48 to the bights 58. The material 58 is then suitably supported and passed to a position over a roller 18 which positions and lays aba'cking material H in con- 68. The backing material tact with the bights is fed from a source of supply or roller 12 and has an adhesive or cementitious material applied to one'surface thereof as at 14 forming the composite structure 83. The composite structure 83 including the backing 14 is then conveyed through the spaced heating or drying units 16 and 11 wherein its fixation and vulcanization to the backed material 58 is completed. The heat supplied by units 68, 82, 83, I6 and 11 may be in the form of superheated steam contained within suitable pipes and fed from a source of supply (not shown). The pipes forming the heating unit 58, 82 53,18 and 11 are enclosed by suitable housings such as as 82 is connected with each housing. The ducts 82 are connected to a suitable air withdrawin means which may be in the form of a fanlnot shown) of suflicient size to continuously withdraw the saturated air formed by subjecting the cementitious material or rubber cement applied to thebackings'to the heated areas formed by the heating units. In this manner the solvent I contained in the cementitious material or rubher cement is immediately removed avoiding skin drying of the cement and insuring the proper bonding of the backings to the bights of the folds of the plaited materials. The spacing of the folds produced by the temporary use of the supporting web 38 aids materially in the removal of the solvent and the proper fixation of the fibers to the backings.

5 For the purpose of increasing the rate and speed at which the pile fabric is suction nozzles or members 84 sides or open ends of the composite structure 83 may be used so as to insure that the drying of the cement and removal of any solvent remaining in the composite structure will be effectively accomplished. However, it

produced,. one or more while the same is passed through the heating units is secured in a comparatively short time. After this optional drying step is effected, the composite structure 83 is then conveyed to a cutting or splitting mechanism which is preferably in the form of a self-sharpening belt knife 81 which is so located as to sever longitudinally between the producing two similar pile fabrics 85 and 86 having upstanding rows of fibers permanently anchored to a backing material. The rows of fibers constituting the pile fabrics by the leg portions 8| and 92 as well as 93 and 94 of U-shaped loops which have the bight portions :38 and 88 cemented to the backing materials 48 and II respectively. The pile fabrics 85 and 36 after the cutting step maybe then subjected to the usual finishing steps which may include desired.

that the plaited material beand a conduit or duct such positioned at the should be noted thatdue to the predetermined spacing of the folds the structure 'backings 48 and II and 88 are formed method of my invention the separation in the rows I shown in Figures 6 and The configurations used in carrying out the imparted to the material hereinbefore described different steps of the are particularly illustrated in detail in Figures 3 to 7 inclusive where it can be seen that the sheet material I! due to the presence of the supporting web 38 when plaited takes the configuration of spaced fold as illustrated inFigure 3. The spacing of the folds is retained when the 'piaited sheet I! is secured to the backing material i8, before the removal of the supporting web 38 so that its removal does'not modify the distinct separation or a space therebetween. As particularly shown in Figure 4, this separation or space between the folds is also retained when the backing. material 'll is'applied' to the other end of the drying and permanent backing fixing steps so that when the platted backed material is cut longitudinally as particularly shown in Figure 5, two similar pile structures are produced.

The resultant in detail in Figure 6-where it can be seen that in the pile'fabric 85 there is a distinct separation or space between the upstanding rows formed by the leg portions 9| and 92 of each loop while the outer. surface of the leg portions of adjacent loops are in contact, thus theupstanding spaced rows are produced by the fibers of the leg portions of adiacentloops. However, it should be noted that forming the vpile fabric I! is present between the leg'portions of adjacent loops while the leg portions 93 and 94 of each of the loops are in close contact as is particularly of the pile fabrics 85 spacing between the rows 7 shown in Figure 6 the and 86 is in alignment as similarity of the same becomes readily apparent.

It should be noted that by the use of the supporting web not only the sheet material used for producing the pile rows is ing its formation during also efiects a substantial saving in the amount of plaited material required for'producing a serves the purpose very eifectively. butother types of sheet material for the stiffening web maybe used, such as cloth or a woven fabric. 7

The invention also contemplates a step wherein the yarn or the material used for plaiting is slightly moistened or softened by steaming. This accomplished bythe use of a steamstep can be other suitable means wherein the ing unit 01 yarns are softened and moistened prior to its passage through the reeds i3 and. I .have

pile fabrics 85 and 86 are shown '7. However. when the prevented from changthe application of the backing material, but that the supporting web plaite'd structure so as to enhance the found that with certain types of yarns when the same are in a soft moist state they will more readily adhere to the'cementing rubber comthe period of time necessary for binding the backing material by means of the rubber cement to the plaited yarns, the moisture acts as a sol vent for the rubber cement and when the yarns are in a soft state the impregnation of the yarns by the rubber cement is deeper, thus enhancing the steaming and softening step.

' It is to be understood that certain steps herein described may be omitted in order to produce a pile fabric having different formation and final appearance than secured to a backing material. It is also contemplated that the application of the second backing be omitted, but the free loops may be cut and subjected to the usual finishing operation so as to produce apile fabric having upstanding fibers of considerable length.

It is apparent that, within the scope of the invention, modificationsand different arrangements may be made other than is herein disclosed, the present disclosure is illustrative merely. the invention comprehending all variations thereof.

What I claim is: I

1. A method of making a pile fabric including pressing said backing material and mat; and removing the relatively still web from said mat.

2. The method of making a pile fabric includweb of paper to form a support therefor; simul and paper material taneously plaiting said sheet to form a structure having spaced folds; cement- 7 ing the folds of said sheet of pile forming material to a backing,'and removing said stiif web of paper.

0. STO'DDARD.

I the one herein described Among others, it is contemplated to omit steps 

